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Yamaha PW80(Z) Owner's Manual

Summary of PW80(Z)

  • Page 1

    3rv-28199-8k pw80(z) owner’s manual manuel du propriÉtaire bedienungsanleitung read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la pre- mière utilisation du véhicule. Bitte lesen sie diese bedienungsanleitung sorgfältig durch, bevor sie das ...

  • Page 2

    Yamaha motor co., ltd. Printed in japan 2009.04–0.2 ×1 ! (e, f, g) printed on recycled paper auf recyclingpapier gedruckt imprimÉ sur papier recyclÉ yamaha motor co., ltd. Printed in japan 2009.04–0.2 ×1 ! (e, f, g) printed on recycled paper auf recyclingpapier gedruckt imprimÉ sur papier recyclÉ.

  • Page 3: 3Rv-28199-8K-E0

    3rv-28199-8k-e0 pw80(z) owner’s manual read this manual carefully before operating this vehicle..

  • Page 4

    Eau48180 read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Ec declaration of conformity conforming to directive 98/ 37/ ec, 2006/42/ec we, yamaha motor co., ltd. 2500 shingai, iwata, japan, declare in sole responsibility, that the prod...

  • Page 5: Introduction

    Introduction eau41582 congratulations on your purchase of the yamaha pw80(z). This model is the result of yamaha’s vast experience in the pro- duction of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reli- ability that have made yamaha a ...

  • Page 6: Introduction

    Introduction an important note to parents: this motorcycle is not a toy. Before you let your child ride this motorcycle, you should understand the instructions and warn- ings in this owner’s manual. Then be sure your child understands and will follow them. Children differ in skills, physical abil- i...

  • Page 7: Important Manual Information

    Important manual information eau10132 particularly important information is distinguished in this manual by the following notations: this is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injur...

  • Page 8: Important Manual Information

    Important manual information eau10200 pw80(z) owner’s manual ©2009 by yamaha motor co., ltd. 1st edition, march 2009 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in japan..

  • Page 9: Table of Contents

    Table of contents location of important labels ............................................. 1-1 safety information .................. 2-1 description .................................. 3-1 left view .......................................... 3-1 right view ........................................ 3...

  • Page 10: Table of Contents

    Table of contents specifications ............................. 9-1 consumer information ........... 10-1 identification numbers .................. 10-1.

  • Page 11: Location of Important Labels

    1-1 1 2 3 4 5 6 7 8 9 location of important labels eau48130 read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replace...

  • Page 12: Location of Important Labels

    Location of important labels 1-2 1 2 3 4 5 6 7 8 9 for europe 4 5pg-2817l-10 100 1.00 15 100 1.00 15 5pg-2816r-00 1 2 3.

  • Page 13: Location of Important Labels

    Location of important labels 1-3 1 2 3 4 5 6 7 8 9 familiarize yourself with the following pictograms and read the explanatory text. **.* kpa *.** kgf/cm² *.* psi **.* kpa *.** kgf/cm² *.* psi read the owner’s manual. This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do...

  • Page 14: Location of Important Labels

    Location of important labels 1-4 1 2 3 4 5 6 7 8 9 for oceania and south africa 1 3 2.

  • Page 15: Location of Important Labels

    Location of important labels 1-5 1 2 3 4 5 6 7 8 9 for oceania and south africa before you operate this vehicle, read the owner’s manual. 5pa-21568-01 prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propriétaire avant d’utiliser ce véhicule. Lesen sie die bedienungsanl...

  • Page 16: Safety Information

    2-1 1 2 3 4 5 6 7 8 9 safety information eau41214 be a responsible owner as the vehicle’s owner, you are respon- sible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are de- pendent upon the use of proper riding techniques as...

  • Page 17: Safety Information

    2-2 2 3 4 5 6 7 8 9 safety information erator is veering wide on a turn due to excessive speed or under- cornering (insufficient lean angle for the speed). Never travel faster than warranted by conditions. ● ride cautiously in unfamiliar ar- eas. You may encounter hidden obstacles that could cause a...

  • Page 18: Safety Information

    2-3 1 2 3 4 5 6 7 8 9 safety information dling if the weight distribution of the mo- torcycle is changed. To avoid the possibility of an accident, use extreme caution when adding accessories to your motorcycle. Use extra care when riding a motorcycle that has added ac- cessories. Here are some gener...

  • Page 19: Safety Information

    2-4 2 3 4 5 6 7 8 9 safety information bar or the front fork area can create instability due to improper weight distribution. If accesso- ries are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. ● bulky or large accessories may seri...

  • Page 20: Description

    3-1 1 2 3 4 5 6 7 8 9 description eau10410 left view 1 2 3 4 5 6 7 1. Air filter element (page 7-8) 2. Fuel cock (page 4-5) 3. Throttle stop screw (page 7-10) 4. Starter (choke) lever (page 4-6) 5. 2-stroke engine oil tank (page 4-4) 6. Sidestand (page 4-8) 7. Shift pedal (page 4-1).

  • Page 21: Description

    Description 3-2 2 3 4 5 6 7 8 9 eau10420 right view 6 1 2 3 4 5 1. Spark arrester (page 7-9) 2. Seat (page 4-7) 3. Transmission oil filler cap (page 7-7) 4. Spark plug cap (page 7-5) 5. Brake pedal (page 4-2) 6. Kickstarter (page 4-6).

  • Page 22: Description

    Description 3-3 1 2 3 4 5 6 7 8 9 eau10430 controls and instruments 1 2 4 3 1. Handlebar switch (page 4-1) 2. Brake lever (page 4-2) 3. Throttle grip (page 7-11) 4. Fuel tank cap (page 4-2).

  • Page 23

    4-1 2 3 4 5 6 7 8 9 instrument and control functions eau40660 handlebar switch eau41130 engine stop switch “engine stop” set this switch to “run” before starting the engine. Set this switch to “off” to stop the engine. Eau41590 power reduction plate your motorcycle was delivered with a power reducti...

  • Page 24

    Instrument and control functions 4-2 1 2 3 4 5 6 7 8 9 eau12890 brake lever the brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handle- bar grip. Eau12941 brake pedal the brake pedal is on the right side of the motorcycle. To apply the rear bra...

  • Page 25

    Instrument and control functions 4-3 2 3 4 5 6 7 8 9 eau13221 fuel make sure there is sufficient gasoline in the tank. Warning ewa10881 gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1. B...

  • Page 26

    Instrument and control functions 4-4 1 2 3 4 5 6 7 8 9 curs, use a gasoline of a different brand or premium unleaded fuel. Use of un- leaded fuel will extend spark plug life and reduce maintenance costs. Eau13412 fuel tank breather hose before operating the motorcycle: ● check the fuel tank breather...

  • Page 27

    Instrument and control functions 4-5 2 3 4 5 6 7 8 9 tank cap and add the recommend- ed oil. 3. Install the 2-stroke engine oil tank cap. Notice eca16670 make sure that the 2-stroke engine oil tank cap is properly installed. 4. Install the seat. Eau13561 fuel cock the fuel cock supplies fuel from th...

  • Page 28

    Instrument and control functions 4-6 1 2 3 4 5 6 7 8 9 this indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “on” after refueling! Eau13590 starter (choke) lever “ ” starting a cold eng...

  • Page 29

    Instrument and control functions 4-7 2 3 4 5 6 7 8 9 eau41140 seat to remove the seat remove the nuts, and then pull the seat off. To install the seat 1. Insert the projection on the front of the seat into the seat holder as shown. 2. Place the seat in the original posi- tion, and then tighten the n...

  • Page 30

    Instrument and control functions 4-8 1 2 3 4 5 6 7 8 9 eau37490 sidestand the sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. Warning ewa14190 the vehicle must not be ridden with the sidestand down, or if the side-...

  • Page 31

    5-1 2 3 4 5 6 7 8 9 for your safety – pre-operation checks eau15596 inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual. Warning ewa11151 failure to in...

  • Page 32

    For your safety – pre-operation checks 5-2 1 2 3 4 5 6 7 8 9 drive chain ● check chain slack. ● adjust if necessary. ● check chain condition. ● lubricate if necessary. 7-16, 7-17 wheels and tires ● check for damage. ● check tire condition and tread depth. ● check air pressure. ● correct if necessary...

  • Page 33

    6-1 2 3 4 5 6 7 8 9 operation and important riding points eau15951 read the owner’s manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your yamaha dealer. Warning ewa10271 failure to familiarize yourself with the controls can lead to l...

  • Page 34

    Operation and important riding points 6-2 1 2 3 4 5 6 7 8 9 eau16660 starting a warm engine follow the same procedure as for start- ing a cold engine with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. Tip if...

  • Page 35

    Operation and important riding points 6-3 2 3 4 5 6 7 8 9 3. Open the throttle gradually. 4. Once the motorcycle has reached a speed high enough to change gears, close the throttle. 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually. 7. Follow the same procedure wh...

  • Page 36

    Operation and important riding points 6-4 1 2 3 4 5 6 7 8 9 eau17191 parking when parking, stop the engine, and then turn the fuel cock lever to “off”. Warning ewa10311 ● since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch ...

  • Page 37

    7-1 2 3 4 5 6 7 8 9 periodic maintenance and adjustment eau41951 periodic inspection, adjustment, and lu- brication will keep your vehicle in the safest and most efficient condition pos- sible. Safety is an obligation of the vehi- cle owner/operator. The most important points of vehicle inspection, ...

  • Page 38

    Periodic maintenance and adjustment 7-2 1 2 3 4 5 6 7 8 9 eau41765 periodic maintenance and lubrication chart tip ● from 160 hours, repeat the maintenance intervals starting from 40 hours. ● items marked with an asterisk should be performed by a yamaha dealer as they require special tools, data and ...

  • Page 39

    Periodic maintenance and adjustment 7-3 2 3 4 5 6 7 8 9 8 * tires check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 9 * wheel bearings check bearings for smooth operation. Replace if necessary. 10 * steering bearings check bearing assemblies for loosen...

  • Page 40

    Periodic maintenance and adjustment 7-4 1 2 3 4 5 6 7 8 9 tip the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 17 * autolube pump check operation. Correct if necessary. 18 transmission oil check for oil leakage. Correct if necessary. Change (warm engine b...

  • Page 41

    Periodic maintenance and adjustment 7-5 2 3 4 5 6 7 8 9 eau19603 checking the spark plug the spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the per...

  • Page 42

    Periodic maintenance and adjustment 7-6 1 2 3 4 5 6 7 8 9 spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tight- en it to the specified torque. Tip if a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 tu...

  • Page 43

    Periodic maintenance and adjustment 7-7 2 3 4 5 6 7 8 9 eau19943 transmission oil the transmission oil level should be checked before each ride. In addition, the transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart. To check the transmission o...

  • Page 44

    Periodic maintenance and adjustment 7-8 1 2 3 4 5 6 7 8 9 notice eca10452 ● in order to prevent clutch slip- page (since the transmission oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “cd” or oils of a higher quality than specified...

  • Page 45

    Periodic maintenance and adjustment 7-9 2 3 4 5 6 7 8 9 4. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the ex- cess oil out. Tip the sponge material should be wet but not dripping. 5. Install the sponge material onto the air filter case cover. 6. ...

  • Page 46

    Periodic maintenance and adjustment 7-10 1 2 3 4 5 6 7 8 9 carbon deposits from the spark ar- rester portion of the tailpipe and in- side of the tailpipe housing. 3. Insert the tailpipe into the muffler, and then install and tighten the bolt to the specified torque. Tip make sure to align the bolt h...

  • Page 47

    Periodic maintenance and adjustment 7-11 2 3 4 5 6 7 8 9 tip if the specified idling speed cannot be obtained as described above, have a yamaha dealer make the adjustment. Eau21370 adjusting the throttle cable free play the throttle cable free play should mea- sure 3.0–5.0 mm (0.12–0.20 in) at the t...

  • Page 48

    Periodic maintenance and adjustment 7-12 1 2 3 4 5 6 7 8 9 eau39821 tires to maximize the performance, durabil- ity, and safe operation of your motorcy- cle, note the following points regarding the specified tires. Tire air pressure the tire air pressure should be checked and, if necessary, adjusted...

  • Page 49

    Periodic maintenance and adjustment 7-13 2 3 4 5 6 7 8 9 sively worn tires decreases riding stability and can lead to loss of control. ● the replacement of all wheel-and brake-related parts, including the tires, should be left to a yamaha dealer, who has the necessary professional knowledge and expe...

  • Page 50

    Periodic maintenance and adjustment 7-14 1 2 3 4 5 6 7 8 9 3. If the specified brake lever free play could be obtained as de- scribed above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt at the brake lever in direction (a) to l...

  • Page 51

    Periodic maintenance and adjustment 7-15 2 3 4 5 6 7 8 9 warning ewa10680 ● after adjusting the drive chain slack or removing and installing the rear wheel, always check the brake pedal free play. ● if proper adjustment cannot be obtained as described, have a yamaha dealer make this ad- justment. ● ...

  • Page 52

    Periodic maintenance and adjustment 7-16 1 2 3 4 5 6 7 8 9 eau22760 drive chain slack the drive chain slack should be checked before each ride and adjusted if necessary. Eau22773 to check the drive chain slack 1. Place the motorcycle on the side- stand. Tip when checking and adjusting the drive chai...

  • Page 53

    Periodic maintenance and adjustment 7-17 2 3 4 5 6 7 8 9 in the specified limits. [eca10571] tip using the alignment marks on each side of the swingarm, make sure that both adjusting nuts are in the same po- sition for proper wheel alignment. 3. Tighten both locknuts and the axle nut to the specifie...

  • Page 54

    Periodic maintenance and adjustment 7-18 1 2 3 4 5 6 7 8 9 eau41842 checking and lubricating the cables the operation of all control cables and the condition of the cables should be checked before each ride, and the ca- bles and cable ends should be lubricat- ed if necessary. If a cable is damaged o...

  • Page 55

    Periodic maintenance and adjustment 7-19 2 3 4 5 6 7 8 9 eau43622 checking and lubricating the brake lever the operation of the brake lever should be checked before each ride, and the lever pivot should be lubricated if nec- essary. Eau23182 checking and lubricating the brake pedal the operation of ...

  • Page 56

    Periodic maintenance and adjustment 7-20 1 2 3 4 5 6 7 8 9 eau23272 checking the front fork the condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main- tenance and lubrication chart. To check the condition check the inner tubes for scratc...

  • Page 57

    Periodic maintenance and adjustment 7-21 2 3 4 5 6 7 8 9 eau23290 checking the wheel bearings the front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica- tion chart. If there is play in the wheel hub or if the wheel does not turn smoothly, ha...

  • Page 58

    Periodic maintenance and adjustment 7-22 1 2 3 4 5 6 7 8 9 frame in front of the rear wheel or under each side of the swingarm. Eau24360 front wheel eau41532 to remove the front wheel warning ewa10821 to avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Remove t...

  • Page 59

    Periodic maintenance and adjustment 7-23 2 3 4 5 6 7 8 9 4. Disconnect the brake cable from the front brake lever. 5. Disconnect the brake cable from the brake camshaft lever. 6. Remove the brake cable free play adjusting bolt and the brake cable locknut at the front wheel hub. 7. Remove the axle nu...

  • Page 60

    Periodic maintenance and adjustment 7-24 1 2 3 4 5 6 7 8 9 3. Insert the wheel axle, and then in- stall the washer and axle nut. 4. Lower the front wheel so that it is on the ground. 5. Connect the brake cable at the wheel hub. 6. Connect the brake cable at the front brake lever. 7. Install the brak...

  • Page 61

    Periodic maintenance and adjustment 7-25 2 3 4 5 6 7 8 9 the brake rod from the brake cam- shaft lever. 3. Disconnect the brake torque rod from the brake shoe plate by re- moving the cotter pin, the nut, and the bolt. 4. Loosen the locknut and drive chain adjusting nut on each end of the swingarm. 5...

  • Page 62

    Periodic maintenance and adjustment 7-26 1 2 3 4 5 6 7 8 9 8. Tighten the axle nut to the speci- fied torque. 9. Adjust the brake pedal free play. (see page 7-14.) eau25851 troubleshooting although yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur d...

  • Page 63

    Periodic maintenance and adjustment 7-27 2 3 4 5 6 7 8 9 eau25972 troubleshooting chart check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Supply fuel. Operate the kickstarter. 2. Compression there is compression. There is no compression. Check the ignition. Have ...

  • Page 64: Motorcycle Care and Storage

    8-1 1 2 3 4 5 6 7 8 9 motorcycle care and storage eau37833 matte color caution notice eca15192 some models are equipped with matte colored finished parts. Be sure to consult a yamaha dealer for advice on what products to use be- fore cleaning the vehicle. Using a brush, harsh chemical products or cl...

  • Page 65: Motorcycle Care and Storage

    Motorcycle care and storage 8-2 2 3 4 5 6 7 8 9 off any detergent residue using plenty of water, as it is harmful to plastic parts. ● do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products...

  • Page 66: Motorcycle Care and Storage

    Motorcycle care and storage 8-3 1 2 3 4 5 6 7 8 9 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it. Warning ewa14501 contaminants on the brakes or tires can cause loss of control. ● make sure that there is no oil or wax on the tires. ● if necessary, was...

  • Page 67: Motorcycle Care and Storage

    Motorcycle care and storage 8-4 2 3 4 5 6 7 8 9 “off”. 3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel ta...

  • Page 68: Specifications

    9-1 1 2 3 4 5 6 7 8 9 specifications eau2633x dimensions: overall length: 1540 mm (60.6 in) overall width: 640 mm (25.2 in) overall height: 880 mm (34.6 in) seat height: 635 mm (25.0 in) wheelbase: 1055 mm (41.5 in) ground clearance: 185 mm (7.28 in) minimum turning radius: 1700 mm (66.9 in) weight:...

  • Page 69: Specifications

    Specifications 9-2 2 3 4 5 6 7 8 9 26.00 ° trail: 62.0 mm (2.44 in) front tire: type: with tube size: 2.50-14 4pr manufacturer/model: cheng shin/knobby rear tire: type: with tube size: 3.00-12 4pr manufacturer/model: cheng shin/knobby loading: maximum rider weight: 40.0 kg (88 lb) tire air pressure ...

  • Page 70: Consumer Information

    10-1 1 2 3 4 5 6 7 8 9 10 consumer information eau40791 identification numbers record the vehicle identification num- ber and model label information in the spaces provided below for assistance when ordering spare parts from a yamaha dealer or for reference in case the vehicle is stolen. Vehicle ide...

  • Page 71: Index

    Index a air filter element, cleaning .........................7-8 autolube pump, adjusting ........................7-19 b brake lever ................................................4-2 brake lever, checking and lubricating ......7-19 brake lever free play, adjusting ...............7-14 brake pedal ...

  • Page 72

    Printed on recycled paper yamaha motor co., ltd. Printed in japan 2009.04–0.2 ×1 ! (e).